Size adjustable headwear piece

ABSTRACT

A headwear piece having a crown with a plurality of gores, including first and second gores, that are joined at a connecting line at a first circumferential location on the crown. The gores cooperatively produce an inverted, cup-shaped receptacle into which a user&#39;s head can be directed. The crown has a bottom portion that extends at least partially around a wearer&#39;s head to embrace the wearer&#39;s head. A sweatband on the crown engages a wearer&#39;s head. The first and second gores are stretchable circumferentially away from the connecting line to thereby increase the diameter of the crown. The sweatband has a portion that is locally non-stretchable at the first circumferential location so that the sweatband and first and second gores are circumferentially stretchable together away from the first circumferential location in response to the direction of a user&#39;s head, with at least a predetermined effective diameter, into the receptacle.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to headwear and, more particularly, to a headwear piece with a crown that is reconfigurable to accommodate different user head sizes.

2. Background Art

Manufacturers of headwear are generally required to accommodate a relatively wide range of user head sizes.

If each headwear piece has a substantially fixed size, a large number of headwear pieces, generally from 8 to 12 in number, may have to be manufactured and kept on hand at point of purchase. This creates problems in turns of inventory control. It is difficult to anticipate demand for particular sizes. As a result, a large number of a particular size may remain on hand while the inventory of other sizes may be exhausted.

It is also difficult to conveniently store the multiple size headwear pieces in a manner whereby they do not take up valuable space, yet at the same time are readily accessible to be offered to a potential purchaser.

The above problems are alleviated to a certain extent by incorporating size adjustment capability into the headwear. Over the years, headwear pieces have been designed to be changeable within a particular size range. This reduces the number of different headwear pieces that must be kept on hand.

One style of headwear piece that has, over the decades, been made with size adjustment capability is a baseball-style cap. Baseball-style caps lend themselves to size adjustment primarily because they normally have fabric crowns that are readily collapsible and reconfigurable.

In a typical baseball-style cap, the crown is constructed by stitching together a plurality of triangularly-shaped gores that collectively produce an inverted cup-shaped receptacle into which a user's head can be directed. An elastic sweatband is stitched to the crown and is folded inside thereof to engage the wearer's head that is embraced by the bottom peripheral surface of the crown.

It is known to produce a cutout in the rear region of baseball-style caps to facilitate size adjustment. The cutout will normally have an inverted “U” shape. A length adjustable strap is caused to span between the legs of the “U”. By varying the effective length of the strap between the legs, the width of the “U” is changed, as a consequence of which the effective diameter of the crown is likewise changed. Many different types of adjustable strap mechanism have been devised to permit this size adjustment.

While this type of size adjustment feature has been effective to potentially afford a significant adjustment range, it has a number of drawbacks. The cutout and strap at the rear of the cap interrupt the continuity of the outer surface of the crown. This may be undesirable from an aesthetic standpoint.

Additionally, the strap adjusting structure may locally, directly engage the wearer's head, which may cause a certain amount of discomfort. For example, if a buckle is incorporated into the strap, the buckle may project into the crown space to press directly against a wearer's head.

Still further, changing of the strap length may cause the crown to noticeably reconfigure and distort. For smaller sizes, particularly, the crown may bunch up in a manner whereby aesthetics are compromised. Also, significant distortion may cause an uncomfortable fit for the user.

As an alternative to the use of an adjustable strap, it is known to construct the gores and sweatband from uniaxially stretchable materials that can be stretched circumferentially around the wearer's head to change effective diameter/size for the crown.

This type of headwear piece typically incorporates a rim/bill at the forward portion of the crown. The rim/bill is commonly made from a material that does not stretch circumferentially. Consequently, the gores and sweatband will stretch minimally, if at all, where they are attached to the rim/bill. Thus, it is known to make the sweatband, in the vicinity of the rim/bill, and the gores attached thereto, with other than the uniaxially stretchable fabric material.

Additionally, it is common to use a minimally stretchable material to define overlying backing tapes that are joined through spaced lines of stitching to adjacent gores. Thus, the gores extend and contract circumferentially effectively only in the region between the stitching lines on adjacent backing tapes.

This type of headwear piece has been commonly made with a sweatband that is stretchable over substantially its full extent between the ends that meet at the rim/bill. Thus, the sweatband remains length adjustable even in the regions where it coincides with the overlying tapes.

As a result of this construction, the gores and sweatband do not reconfigure in the same manner as they conform to different size user heads. This may cause a visible distortion of the crown that detracts from its appearance. This may also result in a less than optimal, comfortable fit for a user.

The industry has not heretofore dealt with the above problems since there has been lacking a construction that adequately overcomes them.

SUMMARY OF THE INVENTION

In one form, a headwear piece is provided having a crown made up of a plurality of gores, including first and second gores that are joined at a connecting line at a first circumferential location on the crown. The gores cooperatively produce an inverted, cup-shaped receptacle with a diameter into which a user's head can be directed with the headwear piece in an operative position. The crown has a bottom portion that extends at least partially around a wearer's head to embrace the wearer's head with the headwear piece in the operative position. A sweatband on the crown engages a wearer's head with the headwear piece in the operative position. The first and second gores are stretchable circumferentially away from the connecting line in response to direction of a user's head, of at least a predetermined effective diameter, into the receptacle so as to thereby increase the diameter of the crown. The sweatband has a portion that is locally non-stretchable at the first circumferential location so that the sweatband and first and second gores are circumferentially stretchable together away from the first circumferential location in response to the direction of a user's head, with at least the predetermined effective diameter, into the receptacle.

In one form, the first and second gores have a first circumferential width at the first circumferential location that is non-stretchable circumferentially in response to direction of a user's head, of at least the predetermined effective diameter, into the receptacle. The sweatband has a second circumferential width at the first circumferential location that is non-stretchable circumferentially in response to direction of a user's head, of at least the predetermined effective diameter, into the receptacle. The headwear piece further includes a backing tape that is attached to the first and second gores either: a) at first and second spaced locations; or b) over a circumferential extent equal to the first circumferential width. The backing tape is substantially non-stretchable in a circumferential direction.

In one form, the sweatband has a stretchable layer and backing tape that is attached to the stretchable layer either at: a) third and fourth locations spaced circumferentially a distance equal to the second circumferential width; or b) over a circumferential extent equal to the second circumferential width. The backing tape that is attached to the stretchable layer is substantially non-stretchable in a circumferential direction.

In one form, the backing tape is attached to the first and second gores by first and second lines of stitching spaced circumferentially by the first width.

In one form, the backing tape that is attached to the stretchable layer is attached by third and fourth lines of stitching spaced circumferentially by the second width.

The first and second widths may be substantially the same and circumferentially aligned.

In one form, the sweatband is attached at the bottom portion of the crown and folded into the receptacle so as to directly engage a wearer's head with the headwear piece in the operative position.

In one form, the headwear piece further has a rim/bill that is attached to the crown and projects in a forward direction away from the crown.

In one form, the rim/bill has a circumferential extent between first and second rim/bill ends and the sweatband includes a stretchable layer that extends at least fully between the first and second edges of the rim/bill over a circumferential portion of the crown at which the rim/bill is not attached.

In one form, the stretchable layer has a vertical width with a top edge and a bottom edge and the backing tape that is attached to the stretchable layer extends over and around at least one of the top edge and bottom edge of the stretchable layer.

In one form, the backing tape that is attached to the stretchable layer extends over and around the top edge of the stretchable layer.

In one form, the crown has a closed top surface.

The crown may have an open top.

In one form, the backing tape is made from a fabric material.

In one form, the gores are made from a uniaxially stretchable material.

In one form, the stretchable layer is made from a uniaxially stretchable material.

In one form, there are at least four gores that make up the crown.

The gores may be joined by stitching along the connecting line.

In one form, the sweatband has a non-stretchable segment extending between the first and second rim/bill ends over a circumferential portion of the crown at which the visor is attached.

In one form, the plurality of gores includes at least one gore that connects to the rim/bill and is non-stretchable in a circumferential direction.

Other objects, features, and advantages of the invention will become apparent from a review of the entire specification, including the appended claims and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic representation of a headwear piece made according to the invention;

FIG. 2 is a perspective view of a headwear piece, as shown in FIG. 1, in the form of a visor;

FIG. 3 is a perspective view of a headwear piece, as shown in FIG. 1, in the form of a baseball-style cap;

FIG. 4 is a view of the cap in FIG. 3 from a different perspective;

FIG. 5 is a bottom view schematically showing connecting lines between gores on a crown on the cap in FIGS. 3 and 4;

FIG. 6 is a bottom view of the cap in FIGS. 3-5;

FIG. 7 is an enlarged, elevation view of a sweatband on the cap in FIGS. 3-6;

FIG. 8 is a cross-sectional view of the sweatband and a backing tape thereon, taken along line 8-8 of FIG. 6;

FIG. 9 is a cross-sectional view of a connection between adjacent gores and a backing tape taken along line 9-9 of FIG. 6; and

FIG. 10 is a cross-sectional view of a connection between adjacent gores and a backing tape taken along line 10-10 of FIG. 6.

DETAILED DESCRIPTION OF THE DRAWINGS

Referring initially to FIG. 1, a headwear piece, according to the present invention, is shown at 10. The headwear piece 10 is shown in schematic form since it is contemplated that the basic components therein might vary considerably from those in the specific embodiments described hereinbelow. The invention encompasses those variations.

The headwear piece 10 consists of a crown 12 defined by a plurality of gores 14 that cooperatively produce a receptacle into which a user's head can be directed to place the headwear piece 10 in an operative position thereon. A sweatband 16 on the crown 12 engages a wearer's head with the headwear piece in the operative position. In the schematic form, no rim/bill is depicted since the invention can be practiced without such a structure. The crown 12 may have a closed top or may be open; the latter being a construction typical of a headwear piece in the form of a visor 18, as shown in FIG. 2.

The inventive concept could be practiced with a visor 18 in substantially the same manner as described hereinbelow for the headwear piece 10 shown in FIGS. 3-10. While the crown 12 may extend continuously around a wearer's head in the operative position therefor, as it does in FIGS. 3-10, the visor 18 is shown with a crown 20 that is interrupted at the back portion 22 thereof.

Referring now to FIGS. 3-10, one preferred form of headwear piece 10, according to the invention, is depicted. The headwear piece 10 in these figures is what is typically referred to as a baseball-style cap. The headwear piece 10 has, in this particular embodiment, six triangularly-shaped gores 14 a, 14 b, 14 c, 14 d, 14 e, 14 f that are joined at connecting lines 24,26,28,30,32,34 at spaced circumferential locations to cooperatively produce an inverted, cup-shaped receptacle 36 into which a user's head can be directed with the headwear 10 in an operative position. The bottom portion 38 of the crown 12 extends fully around, and embraces, a wearer's head to maintain the headwear piece 10 securely in the operative position therefor.

A sweatband 16 resides against the inside surface 40 of the crown 12 bounding the receptacle 36 at the bottom portion 38 of the crown 12. A line of stitching 42 secures a bottom edge 44 of the sweatband 16 at a bottom edge 46 of the crown 12. Through this arrangement, the sweatband 16 can be folded into and out of the receptacle 36 around the stitching line 42. The sweatband 16 could be secured to the gores 14 a-14 f to be at all times maintained against the inside surface 40 bounding the receptacle 36.

In this embodiment, a rim/bill 50 is attached to the crown 12 at a forward portion 52 thereon and projects in a forward direction.

According to the invention, the gores 14 a, 14 b, 14 c, 14 d are made from uniaxially stretchable material that is oriented on the gores 14 a, 14 b, 14 c, 14 d so that they are each stretchable circumferentially, as indicated by the arrows 56,58,60,62, thereby to increase the effective diameter D of the receptacle 36 defined by the crown 20.

A backing/seam tape 66 is applied to the inside surface 40 of the crown 20 to overlie the region of the connecting lines 28,34. The backing tape 66 is attached to the surface 40 through spaced lines of stitching 68,70, shown equidistantly spaced from the connecting lines 28,34 at circumferentially spaced locations. The backing tape 66 is made from a non-stretchable material, or at least one does not stretch in a circumferential direction.

It should be understood that the distinction between “stretchable” and “non-stretchable” relates to a degree of stretching capability. Virtually every material contemplated for use will have a certain ability to stretch under a circumferential force. However, it is contemplated that in response the circumferential forces generated by a user's pressing his/her head, of at least a predetermined effective diameter, into the receptacle 36, the exemplary gores 14 c, 14 d will circumferentially stretch away from the connecting line 28, and more particularly the lines of stitching 68,70. By attaching the backing tape 66, the gores 14 c, 14 d become non-stretchable in a circumferential direction over a width W between the lines of stitching 68,70 at the location where the backing tape 66 overlies these gores 14 c, 14 d.

Similar lengths of backing tape 66 a,66 b respectively overlie the connecting lines 26,32; and 24,30. They function in the same manner between the gores 14 b, 14 c; and 14 a, 14 b, respectively.

The crown 12 is designed to stretch, thereby to increase the effective diameter D of the receptacle 36 in response to the direction of a user's head, of at least the aforementioned predetermined effective diameter, into the receptacle 36. As this occurs, the gores 14 a, 14 b, 14 c, 14 d simultaneously stretch circumferentially to effectively enlarge the diameter D. As this occurs, the gore 14 d stretches circumferentially away from the connecting line 28 and, more particularly, the line of stitching 70, while the gore 14 c stretches circumferentially oppositely away from the connecting line 28 and, more particularly, the line of stitching 68. The gores 14 b, 14 c stretch in the same manner away from the connecting line 26 and corresponding lines of stitching 68′,70′. Likewise, the gores 14 a, 14 b stretch away from the connecting line 24 and the lines of stitching 68″,70″.

While the gores 14 e, 14 f could be made from a stretchable material, more preferably the material thereof is circumferentially nonstretchable. That is because each of these gores 14 e, 14 f is connected to the rim/bill 50 that is substantially non-stretchable in a circumferential direction. Accordingly, while on one half of the crown 12 the gore 14 a is stretchable circumferentially away from the connecting line 34, and more specifically from the line of stitching 68, and the gore 14 b is circumferentially stretchable away from the connecting line 24, and the line of stitching 70″, the gores 14 e, 14 f remain substantially fixed in circumferential dimension.

The sweatband 16 may be made in one or multiple pieces. In the one-piece construction, the sweatband 16 has lengths of backing tape 76,76′,76″,76′″,76″″ strategically attached thereto to limit circumferential stretching of the sweatband 16 locally over a width W1 corresponding to the dimension W over which the backing tape 76 is attached to the sweatband 16.

In this embodiment, the widths W,W1 overlap and more preferably are equal in circumferential extent and in full circumferential registration.

At the exemplary location where the backing tape 76 is shown, separate lines of stitching 78,80 attach the backing tape 76 to a stretchable layer 81 on the sweatband 16. As shown, the lines of stitching 76,78 align with the lines of stitching 68,70 on the backing tape 66. The backing tape 76 is likewise non-stretchable in a circumferential direction so that in response to a user's head, of the aforementioned predetermined effective diameter, being directed into the receptacle 36, the exemplary gores 14 c, 14 d stretch away from the lines of stitching 68,70, while segments 82,84 of the layer 81 on the sweatband 16 stretch circumferentially oppositely away from the lines of stitching 78,80 as indicated by the arrows 85. Accordingly, the gores 14 c, 14 d and sweatband segments 82,84 stretch in a corresponding manner, with neither stretching circumferentially where the backing tapes 66,76 are attached over the respective widths W,W1.

The backing layers 76′,76″,76′″,76″″ are connected to the sweatband layer 81 in a similar fashion.

In one form, as shown most clearly in FIG. 8, the backing layer 76 is wrapped over and around the top edge 86 of the sweatband layer 81. An end 88 of the backing tape 76 is doubled back, with the lines of stitching 78,80 directed therethrough.

While spaced lines of stitching define the widths W,W1 over which the gores become non-stretchable, as an alternative to this construction, the backing tapes may be fixed, as by an adhesive or otherwise, over the appropriate width to cause the associated gores to be non-stretchable.

As seen additionally in FIG. 6, the sweatband 16 may have a segment 92, circumferentially corresponding to the dimension of the rim/bill 50 between the ends 96,98, that is non-stretchable in a circumferential direction.

The sweatband 16 may be made from one or more layers 81 that are stretchable in a circumferential direction. Woven elastic bands are well known for this application. It is contemplated that the sweatband 16 will directly engage a wearer's head with the headwear piece 10 in the operative position thereon.

The gores 14 a-14 f and sweatband 16 may be made to be uniaxially stretchable in a circumferential direction or may alternatively be universally stretchable. The former is preferred. As one example, the gores 14 a-14 f may be made from fabric that is single woven with polyurethane or spun yarn as the weft to provide the circumferential stretching capability. Weft yarns, that are covered with polyurethane or spandex, are known and usable for the crown fabric.

The backing tape can likewise be made from a non-stretchable fabric.

There is no particular limitation as to how the individual gores 14 a-14 d are formed or connected. In one exemplary form, the gores 14 a, 14 b, 14 c, 14 d are connected to each other in the same manner as shown at the connecting line 28 in FIG. 9. The gore 14 c has a main body 104 and an under-folded portion 106. The gore 14 d has a main body 108 and an under-folded portion 110. A line of stitching 112 connects the gores 14 c, 14 d by uniting abutted edges between the bodies 104, 108 and under-folded portions 106, 110. The line of stitching 68 extends through the body 104, under-folded portion 106 and backing tape 66, with the line of stitching 70 extending through the body 108, under-folded portion 110 and backing tape 66.

The gores 14 a, 14 f and 14 d, 14 e are joined at their respective connecting lines 34, 30 in the same manner, as seen most clearly in FIG. 10. At the exemplary connecting line 30, between the gores 14 d, 14 e, the gore 14 d has an under-folded portion 114. The under-folded portion 114 overlies the gore 14 e under which the backing tape 66 b is located. The line of stitching 68″ extends through and unites the main body 116 of the gore 14 d, the under-folded portion 114, the gore 14 e and the backing tape 66 b. The line of stitching 70″ extends through the gore 14 e and backing tape 66 b.

Again, it should be noted that this is just one preferred method of connecting the gores 14 a-14 f. Virtually any type of structure that joins the gores 14 a-14 f is contemplated, among which is an adhesive bonding of components. It is conceivable that a tape could be used to maintain the gores 14 a-14 f together without otherwise directly stitching the gores 14 a-14 f, one to the other.

The foregoing disclosure of specific embodiments is intended to be illustrative of the broad concepts comprehended by the invention. 

1. A headwear piece comprising: a crown comprising a plurality of gores, including first and second gores that are joined at a connecting line at a first circumferential location on the crown, to cooperatively produce an inverted cup-shaped receptacle with a diameter into which a user's head can be directed with the headwear piece in an operative position, the crown having a bottom portion that extends at least partially around a wearer's head to embrace a wearer's head with the headwear piece in the operative position; and a sweatband on the crown that engages a wearer's head with the headwear piece in the operative position, the first and second gores stretchable circumferentially away from the connecting line in response to direction of a user's head of at least a predetermined effective diameter into the receptacle so as to thereby increase the diameter of the crown, the sweatband having a portion that is locally non-stretchable at the first circumferential location so that the sweatband and first and second gores are circumferentially stretchable together away from the first circumferential location in response to the direction of a user's head, with at least the predetermined effective diameter, into the receptacle.
 2. The headwear piece according to claim 1 wherein the first and second gores have a first circumferential width at the first circumferential location that is non-stretchable circumferentially in response to direction of a user's head of at least the predetermined effective diameter into the receptacle, and the sweatband has a second circumferential width at the first circumferential location that is non-stretchable circumferentially in response to direction of a user's head of at least the predetermined effective diameter into the receptacle, the headwear piece further comprising a backing tape that is attached to the first and second gores either: a) at first and second spaced locations; or b) over a circumferential extent equal to the first circumferential width, the backing tape substantially non-stretchable in a circumferential direction.
 3. The headwear piece according to claim 2 wherein the sweatband comprises a stretchable layer and backing tape that is attached to the stretchable layer either at: a) third and fourth locations spaced circumferentially a distance equal to the second circumferential width; or b) over a circumferential extent equal to the second circumferential width, the backing tape that is attached to the stretchable layer substantially non-stretchable in a circumferential direction.
 4. The headwear piece according to claim 2 wherein the backing tape is attached to the first and second gores by first and second lines of stitching spaced circumferentially by the first width.
 5. The headwear piece according to claim 3 wherein the backing tape that is attached to the stretchable layer is attached by third and fourth lines of stitching spaced circumferentially by the second width.
 6. The headwear piece according to claim 3 wherein the first and second widths are substantially the same and circumferentially aligned.
 7. The headwear piece according to claim 3 wherein the sweatband is attached at the bottom portion of the crown and folded into the receptacle so as to directly engage a wearer's head with the headwear piece in the operative position.
 8. The headwear piece according to claim 1 wherein the headwear piece further comprises a rim/bill that is attached to the crown and projects in a forward direction away from the crown.
 9. The headwear piece according to claim 8 wherein the rim/bill has a circumferential extent between first and second rim/bill ends and the sweatband comprises a stretchable layer that extends at least fully between the first and second edges of the rim/bill over a circumferential portion of the crown at which the rim/bill is not attached.
 10. The headwear piece according to claim 3 wherein the stretchable layer has a vertical width with a top edge and a bottom edge and the backing tape that is attached to the stretchable layer extends over and around at least one of the top edge and bottom edge of the stretchable layer.
 11. The headwear piece according to claim 10 wherein the backing tape that is attached to the stretchable layer extends over and around the top edge of the stretchable layer.
 12. The headwear piece according to claim 1 wherein the crown has a closed top surface.
 13. The headwear piece according to claim 1 wherein the crown has an open top.
 14. The headwear piece according to claim 2 wherein the backing tape comprises a fabric material.
 15. The headwear piece according to claim 1 wherein the gores are made from a uniaxially stretchable material.
 16. The headwear piece according to claim 3 wherein the stretchable layer is made from a uniaxially stretchable material.
 17. The headwear piece according to claim 1 wherein there are at least four gores that make up the crown.
 18. The headwear piece according to claim 1 wherein the gores are joined by stitching along the connecting line.
 19. The headwear piece according to claim 9 wherein the sweatband comprises a non-stretchable segment extending between the first and second rim/bill ends over a circumferential portion of the crown at which the rim/bill is attached.
 20. The headwear piece according to claim 8 wherein the plurality of gores includes at least one gore that connects to the rim/bill and is non-stretchable in a circumferential direction. 